Table of Contents
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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-
egories could lead to serious problems.
and
areas are
denoted to emphasize certain areas and carry the following meanings:
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
K6
99505-01066-01E
December '05 Printed in Japan (TK) 19
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Table of Contents
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Summary of Contents for Suzuki GSF1200SK6
- Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
- Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
- Page 3 Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle. Handling crates requires two operators. Be careful not to scratch the motorcycle. A: Steel frame B: Crate base...
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Page 4: Location Of Parts
LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Windscreen Handlebar balancer Right and Left weight Stepped Allen screw 5 × 18 mm Screw 6 ×... - Page 5 RIGHT LEFT The photographs shown indicates the parts dis- mounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly C: Left switch Choke cable D: Clutch master cylinder...
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Page 6: Removing The Bracket
Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 32. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY LEFT RIGHT REMOVING THE BRACKET Remove the bolts to take off the front brake and clutch master cylinder from the bracket. - Page 7 HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. A: Throttle assembly B: Handlebars Install the handlebars assembly using the two clamps, four Allen bolts and washers. NOTE: Install the burring washer in the direction as shown in the illustration.
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Page 8: Front Brake Master Cylinder
The line drawings on page 29, 30 and 31 show the proper routing of the control cables, hose and wirings. Refer to them in addition to following the instructions carefully. A: Front brake hose B: Throttle cables C: Right switch wiring harness D: Clutch hose E: Left switch wiring harness F: Choke cable... -
Page 9: Front Brake Hose
NOTE: Install the holder in position according to the mark “UP”. Make sure that the holder has no clearance at the upper side as shown. Check for brake fluid leakage. A: Bolt B: Holder C: Front brake master cylinder D: Handlebars Connect the front brake light switch lead wires coupler to the brake light switch. -
Page 10: Clutch Master Cylinder
Insert the choke cable into the hole of lower housing. Insert the choke cable end into the recess in the choke lever. NOTE: Before installing the cable, grease its cable end. A: Choke cable end B: Hole C: Lower housing D: Choke lever Insert the boss of lower housing into the hole on the handlebars. - Page 11 NOTE: Install the holder in position according to the mark “UP”. Make sure that the holder has no clearance at the upper side as shown. Check for clutch fluid leakage. A: Bolt B: Holder C: Clutch master cylinder D: Handlebars Connect the clutch lever position switch lead wires to the clutch lever position switch.
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Page 12: Cable Guide
CABLE GUIDE Pass the clutch hose, choke cable and left switch wir- ing harness through the cable guide. Install the cable guide to the front fork upper bracket. A: Cable guide B: 6 × 12 mm flange bolt C: Clutch hose D: Left switch wiring harness E: Choke cable... - Page 13 Place the motorcycle on the center-stand, then remove the hoist hook. WINDSCREEN Remove the screws. A: Meter assembly B: Stepped Allen screw Remove the boss and hook of meter assembly. Disconnect the meter assembly coupler to take off the meter assembly. A: Meter assembly B: Boss C: Hook...
- Page 14 Set the windscreen between the rubber cushion and meter panel. A: Windscreen B: Meter panel C: Meter brace D: Rubber cushion (with nut) Tighten the screws to fix the windscreen to the meter panel. A: Windscreen B: Meter panel C: Meter brace D: Rubber cushion (with nut) E: 5 ×...
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Page 15: Rear View Mirror
REAR VIEW MIRROR Install the rear view mirror to the front fairing. Fit the plastic cap on the head of each bolt. NOTE: Align the mirror in the position so as to secure rear view. A: Rear view mirror assembly B: 6 ×... -
Page 16: Warning Label
WARNING LABEL (FOR E-19 CC AND E-19 CD SELECTION) Select the appropriate language label for your country. NOTE: For E-19 CC selection: seven kinds of labels, English, French, German, Spanish, Portu- guese, Dutch, and Italian, are supplied together with M/C. For E-19 CD selection: four kinds of labels, Finnish, Norwegian, Danish and Swedish, are supplied together with M/C. - Page 17 SERVICING BATTERY The battery is located under the seat. Remove the seat using the key. A: Seat lock B: Seat Remove the rubber band. Remove the battery from the motorcycle. A: Rubber band Filling electrolyte Remove the aluminium tape sealing the battery elec- trolyte filler holes.
- Page 18 Remove the caps from the electrolyte container. NOTE: Use the removed caps as the sealed caps of battery filler holes. Do not remove or pierce the sealed areas of the electrolyte container. A: Caps B: Sealed area With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall.
- Page 19 After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes. Insert the caps into the filler holes, pressing in firmly so that the top of the each caps does not protrude above the upper surface of the battery’s top cover.
- Page 20 Remove the frame covers. A: Frame cover B: Stepped Allen screw C: Boss 1. Reinstall the battery in the motorcycle. + lead to the + positive terminal 2. First connect the of the battery. + terminal with rubber boot.
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Page 21: Brake Fluid
FRONT REAR BRAKE FLUID Keep the motorcycle upright and place the handlebars straight. Check the brake fluid level in both the front and rear master cylinder reservoirs. If the fluid level is below the lower level indicated in the figure, add the correct type of brake fluid. Refer to the chart below for the proper selection. -
Page 22: Clutch Fluid
REAR The procedure to bleed the rear brake is identical to that of the front. Rear brake caliper air bleeder valve: 6.0 N·m (0.60 kgf-m) A: Bleeder valve CLUTCH FLUID Keep the motorcycle upright and place the handlebars straight. Check the clutch fluid level in the master cylinder res- ervoir. -
Page 23: Front Brake Lever
FRONT BRAKE LEVER Make sure the front brake lever position is correct. The standard setting for this motorcycle is as indicated in the table below. Standard setting Position 3 A: Adjuster CLUTCH LEVER Make sure the clutch lever position is correct. The standard setting of this motorcycle is as indicated in the table below. -
Page 24: Rear Brake Pedal
REAR BRAKE PEDAL Check the rear brake pedal height. Rear brake pedal height: 55–65 mm If the rear brake pedal height is not correct, adjust in the following manner: 1. Loosen the lock nut B to locate the pedal to the 2. -
Page 25: Front Suspension
FRONT SUSPENSION Checking spring setting Make sure the spring setting of the front suspension is correct. The standard setting for this motorcycle is as indicated in the table below. Standard setting Position 3 Check that right and left spring settings are in the same position. -
Page 26: Tire Pressure
TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires. The pressure should be as shown. COLD INFLATION TIRE PRESSURE SOLO RIDING DUAL RIDING 250 kPa 250 kPa FRONT 2.50 kgf/cm 2.50 kgf/cm 36 psi 36 psi... - Page 27 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization ENGINE OIL VISCOSITY RATING SELECTION CHART SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the following chart.
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Page 28: Idle Speed Adjustment
Energy Conserving Suzuki does not recommend the use of “ENERGY CONSERVING” oils. Some engine oils which is API SH or greater has “ENERGY CONSERVING” indication in API classifica- tion doughnut mark. 10W-40 10W-40 These oils can affect engine life and clutch perform- ance. -
Page 29: Tightening Torque
TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK Rear brake push rod lock nut Handlebar clamp bolt Brake caliper air bleeder (Front) 0.75 Steering stem head nut Brake caliper air bleeder (Rear) 0.60 Handlebar holder nut AXLE Front fork upper bracket bolt Front axle bolt... -
Page 30: Harness Routing
HARNESS ROUTING Clamp Handlebar switch lead wire (L) Choke cable Speed sensor lead wire Battery Clutch hose Ignitor Clamp Cable guide Choke cable Throttle cable Gear position switch coupler Ignition coil Clamp Carburetor heater lead wire Clamp Thermo switch lead wire Cable guide Clamp Turn signal light lead wire... - Page 31 Wiring harness Clamp Turn signal light lead wire (L) Clutch hose Turn signal light lead wire (R) Clamp Wiring harness Speed sensor lead wire Neutral switch lead wire Clutch hose Starter relay Starter motor lead wire Signal generator lead wire Side stand switch lead wire Neutral switch lead wire Starter motor lead wire...
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Page 32: Cable Routing
CABLE ROUTING 3 - 5 mm Throttle cable (Pulling cable) Throttle cable (Returning cable) Cable guide Cable guide Cable adjuster 0 mm 0 mm 0 mm 0 mm Cable guide Choke cable Clutch hose Throttle cable (Pulling cable) Throttle cable (Returning cable) Pass the choke cable through between the pulsed secondary air injection hoses Pass the throttle cable through the right lower of hose... -
Page 33: Safety Check-Out
SAFETY CHECK OUT ELECTRICALS ITEM CHECK FOR After completion of the setting-up the motorcy- Light cle all the following items should be double- Headlight high/low beam Lighting/Adjust checked to confirm that the operation and func- Tail/Brake light tion of the motorcycle are satisfactory. Now, Turn signal light setting-up the motorcycle and pre-delivery Position light...